Method and Apparatus for Making Absorbent Articles Having Side Seams

ABSTRACT

The present disclosure relates to methods and apparatuses for manufacturing absorbent articles, and more particularly, apparatuses and methods utilizing multiple processing stations for processing absorbent articles and being configurable to move along various predetermined travel paths defined by radii that may be constant or variable. Particular embodiments of apparatuses and methods of manufacture include a processing wheel having a plurality of processing stations which orbit around a rotation axis. The processing stations may be configured to perform various types of operations associated with the manufacture of absorbent articles while the processing stations orbit around the rotation axis. The processing wheel can be configured to adjust the path along which the processing stations orbit as the processing wheel rotates around the rotation axis. As such, the orbit path can be adjusted to accommodate the manufacture of different sized blanks without the need to physically move or relocate and realign other process apparatuses, such as for example, sealing stations.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses formanufacturing absorbent articles, and more particularly, apparatuses andmethods utilizing multiple rotating stations for processing absorbentarticles and being configurable to move along various predeterminedpaths defined by varying radii.

BACKGROUND OF THE INVENTION

Infants and other incontinent individuals wear disposable absorbentarticles such as diapers to absorb and retain urine and other bodyexudates. Absorbent articles may function both to contain the dischargedmaterials and to isolate these materials from the body of the wearer andfrom the wearer's garments and bed clothing.

Diapers can be configured to fit on a wearer's body in various ways. Forexample, some diaper may be configured as pull-on pant-type diapers ortraining pants. Diapers, such as training pants, may be used withinfants prior to and/or during toilet training. Training pants may beconfigured with a “closed” chassis configuration, in which the chassisis adapted to be pulled on over the legs and lower torso of the wearerwithout any additional fastening steps.

Closed chassis diapers may be manufactured with a front ear being seamedto a back ear to form the closed chassis. In some configurations, closedchassis diapers may also have manually tearable side seams. The sideseams may be configured as butt-type seams or overlapping side seams.

During the manufacturing process, a closed chassis diaper may bemanufactured from a blank cut to a particular configuration and size.Manufacturing processes may involve some type of sealing step to createside seams in the diapers. For example, after being fully assembled, theblank may be folded along a central transverse area and the sides of thefront and rear panels are seamed together to form a closed chassisdiaper. In other processes, the side seams may be formed by folding thechassis in a crotch portion so that longitudinal side regions of thefront portion and rear portion are superposed to form seaming areas,which are then treated with ultrasonic energy to sever the material inthe seaming area in a first area while simultaneously bonding thematerial of the seaming area in a marginal area adjacent the first areato form a flangeless seam.

In some manufacturing configurations, the seaming and folding operationsmay be performed automatically on a processing wheel having a pluralityof folding stations and associated seaming mechanisms. Various types ofsuch processing wheels have been described in U.S. Patent PublicationNo. 2008/0083489 and U.S. Pat. Nos. 5,779,831 and 7,322,925. Theprocessing wheels provide the ability to produce training pants a highrate of speed. However, reconfiguring various components of theprocessing wheel to change manufacturing operations for different sizesof absorbent articles can be onerous. For example, some components ofthe processing wheel may require realignment, which can be timeconsuming and expensive. For instance, different size folding stationsmay be needed to accommodate a different sized diaper. Such differentsized folding stations may need to be realigned with the seamingstations. In addition, different sized folding stations may also requirechanges in the physical locations of operating stations, such as thedischarge station, located adjacent the processing wheel.

SUMMARY OF THE INVENTION

Aspects of the present disclosure relate to methods and apparatuses formanufacturing absorbent articles, and more particularly, apparatuses andmethods utilizing multiple processing stations for processing absorbentarticles and being configurable to move along various predeterminedtravel paths defined by radii that may be constant or variable.

In one form, an apparatus for making absorbent articles having sideseams includes: a wheel adapted to rotate about a rotation axis; a firsttrack defining a first circumferential shape surrounding the rotationaxis, wherein the first track is stationary relative to the wheel; asecond track defining a second circumferential shape surrounding therotation axis, wherein the second track is stationary relative to thewheel; and a plurality of folding mechanisms disposed on the wheel. Eachfolding mechanism includes: a first follower member movably connectedwith the first track, the first follower member having a proximal endportion and a distal end portion; a carrier arm pivotally connected withthe first follower member; a gripper member connected with the carrierarm; and a second follower member connected with the carrier arm andmovably connected with the second track. As the wheel rotates, thedistal end portion of the first follower member orbits in a first orbitpath about the rotation axis in correspondence with the firstcircumferential shape, and the second follower member moves relative tothe first follower member in correspondence with a relative radialdistance between the first track and the second track.

In another form, an apparatus for making absorbent articles having sideseams includes: a wheel adapted to rotate about a rotation axis; a firsttrack defining a first circumferential shape surrounding the rotationaxis, wherein the first track is stationary relative to the wheel; and aplurality of folding mechanisms disposed on the wheel. Each foldingmechanism includes: a first follower member movably connected with thefirst track, the first follower member having a proximal end portion anda distal end portion; a carrier arm pivotally connected with the firstfollower member; and a gripper member connected with the carrier arm. Asthe wheel rotates, the carrier arm is selectively pivoted relative tothe first follower member, and the distal end portion of the firstfollower member orbits in a first orbit path about the rotation axis incorrespondence with the first circumferential shape, wherein the firstorbit path is defined a varying distance from the rotation axis.

In yet another form, a method of making absorbent articles having sideseams includes the steps of: cutting a web into discrete blanks;transferring the blanks onto folding mechanisms disposed on a wheelrotating around a rotation axis, wherein each folding mechanismcomprises: a first follower member movably connected with the firsttrack, the first follower member having a proximal end portion and adistal end portion, a carrier arm pivotally connected with the firstfollower member, a gripper member connected with the carrier arm, and asecond follower member connected with the carrier arm and movablyconnected with the second track; moving the distal end portion of thefirst follower member in a first orbit path about the rotation axis incorrespondence with a first circumferential shape defined by the firsttrack; and actuating the folding mechanisms to fold the blanks by movingthe second follower member relative to the first follower member incorrespondence with a relative radial distance between the first trackand the second track.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an absorbent article having overlapping side seams.

FIG. 1 a shows a detailed view of a side seam of FIG. 1.

FIG. 2 shows an article having butt-type side seams.

FIG. 2 a shows a detailed view of a side seam of FIG. 2.

FIG. 3 shows a top plan view of a blank for forming an absorbent articlehaving side seams.

FIG. 4 shows a cross-sectional view of the blank of FIG. 3 taken alongline IV-IV.

FIGS. 4 a-4 e show cross-sectional views of different embodiments ofblanks for forming articles having side seams.

FIG. 5 a process diagram of a processing wheel for forming seamedarticles.

FIG. 6 a is an isometric view of a processing station of a processingwheel.

FIG. 6 b is a top elevational view of the processing station of FIG. 6a.

FIG. 6 c is a partial cross sectional view of the processing wheel ofFIG. 6 a taken along line I-I.

FIG. 6 d is a partial cross sectional view of the processing wheel ofFIG. 6 c taken along line II-II.

FIG. 6 e is a view of a folding mechanism in an extended position.

FIG. 6 f is a view of a folding mechanism in a retracted position.

FIG. 7 a shows a schematic top view of a gripper and sealer in formationof a butt-type side seam.

FIG. 7 b shows a schematic top view of a gripper and sealer in formationof a combined overlapping and butt-type side seam.

FIG. 7 c shows a schematic top view of a gripper and sealer in formationof a three-layer overlapping side seam.

FIG. 8 a is a schematic side view of a processing wheel configured forfolding and seaming relatively small size blanks.

FIG. 8 b is an outline showing the orbital path of the folding stationsof FIG. 8 a.

FIG. 9 a is a schematic side view of a processing wheel configured forfolding and seaming relatively large size blanks.

FIG. 9 b is an outline showing the orbital path of the folding stationsof FIG. 9 a.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

The term “body facing surface” refers to surfaces of absorbent articlesand/or components thereof which face a wearer's body when the absorbentarticles are worn, and the term “garment facing surface” refers tosurfaces of absorbent articles and/or components thereof that face awayfrom a wearer's body when the absorbent articles are worn. Absorbentarticles and components thereof, including topsheets, backsheets,absorbent cores, and any individual materials of their components, havea body facing surface and a garment facing surface.

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a layer or layers or fibrousmaterials, films and foils such as plastic films or metallic foils thatmay be used alone or laminated to one or more web, layer, film and/orfoil. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, and the like.Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. The term “cross direction”(CD) is used herein to refer to a direction that is generallyperpendicular to the machine direction.

As used herein the term “stretchable” refers to materials which canstretch to at least an elongated length of 105% on the upcurve of thehysteresis test at a load of about 400 gm/cm. The term “non-stretchable”refers to materials which cannot stretch to at least 5% on the upcurveof the hysteresis test at a load of about 400 gm/cm.

The terms “elastic” and “elastomeric” as used herein refer to anymaterial that upon application of a biasing force, can stretch to anelongated length of at least about 110% of its relaxed, original length(i.e. can stretch to 10% more than its original length), without ruptureor breakage, and upon release of the applied force, recovers at leastabout 40% of its elongation. For example, a material that has an initiallength of 100 mm can extend at least to 110 mm, and upon removal of theforce would retract to a length of 106 mm (40% recovery). The term“inelastic” refers herein to any material that does not fall within thedefinition of “elastic” above.

The term “extensible” as used herein refers to any material that uponapplication of a biasing force, can stretch to an elongated length of atleast about 110% of its relaxed, original length (i.e. can stretch to10%), without rupture or breakage, and upon release of the appliedforce, shows little recovery, less than about 40% of its elongation.

The terms “activating”, “activation” or “mechanical activation” refer tothe process of making a substrate, or an elastomeric laminate moreextensible than it was prior to the process. “Live stretch” includesstretching elastic and bonding the stretched elastic to a substrate.After bonding, the stretched elastic is released causing it to contract,resulting in a “corrugated” substrate. The corrugated substrate canstretch as the corrugated portion is pulled to about the point that thesubstrate reaches at least one original flat dimension. However, if thesubstrate is also elastic, then the substrate can stretch beyond therelaxed length of the substrate prior to bonding with the elastic. Theelastic is stretched at least 25% of its relaxed length when it isbonded to the substrate.

Aspects of the present disclosure relate to methods and apparatuses formanufacturing absorbent articles, and more particularly, apparatuses andmethods utilizing multiple processing stations for processing absorbentarticles and being configurable to move along various predeterminedtravel paths defined by radii that may be constant or variable.Particular embodiments of apparatuses and methods of manufacturedisclosed herein include a processing wheel having a plurality ofprocessing stations which orbit around a rotation axis. The processingstations may be configured to perform various types of operationsassociated with the manufacture of absorbent articles while theprocessing stations orbit around the rotation axis. For example, in someembodiments, separate pre-forms, or blanks, from which absorbentarticles are formed, may be transferred to the orbiting processingstations from another apparatus used in the manufacturing process, suchas an anvil roll. As the processing stations move along an orbit path,the processing stations may perform various operations, such as foldingthe blanks and superimposing sealing areas on the folded blanks. Theprocessing stations may also move the sealing areas into a position to adesired alignment with a sealing station where the sealing areas areconnected. Once the processing stations have performed the requiredoperations, the folded blanks in the form of absorbent articles may bemoved from the processing wheel to another apparatus used in themanufacturing operation. In accordance with the present disclosure, theprocessing wheel can be configured to adjust the path along which theprocessing stations orbit as the processing wheel rotates around therotation axis. As such, the orbit path can be adjusted to accommodatethe manufacture of different sized blanks without the need to physicallymove or relocate and realign other process apparatuses, such as forexample, sealing stations.

With reference to FIGS. 1-4, a description of various types of articlesthat may be produced in accordance with the methods and apparatusesdisclosed herein is provided below to provide a context for subsequentdescriptions relating to the operation and structural featuresembodiments of the processing wheel and processing stations andassociated manufacturing processes. Although the following descriptionrefers to disposable absorbent articles, in which a backsheet, anabsorbent core, and a liquid permeable topsheet are combined to form anintegral structure, it is to be appreciated that various types ofarticles may be produced in accordance with the methods and apparatusesdescribed herein. As such, absorbent articles referred to herein mayinclude a single layer or multiple layers of woven or nonwoven materialand may include a thermoplastic film. In some instances, the articlesmay be constructed as a reusable diaper holder that is to be used incombination with a disposable absorbent insert core.

FIGS. 1 and 2 show an absorbent article 100, which may be in the form ofa diaper 102 illustrated as a pull-on type diaper, having a front panel104 and a back panel 106 joined together to define leg openings 108, 110and a waist opening 112. The diaper 102 also includes an inner, bodyfacing surface 114, and an outer, garment facing surface 116. During themanufacturing process, the absorbent article 100 may be made from apre-form, or blank 118, that is folded along a transverse center line120 and having side seams 122, 124 connect the front panel and backpanel together. The pre-form 118 is alternatively referred to herein asa blank 118. As discussed in more detail below, embodiments of aprocessing wheel, and more particularly, processing stations on aprocessing wheel fold the blanks 118 and position the folded blanks forconnection of the side seams 122, 124.

It is to be appreciated that various configurations of side seams may beused to connect the front and back panels together. For example, theside seams 122, 124 shown in FIGS. 1 and 1 a are configured asoverlapping side seams 126, 128, which are formed by overlappingportions of the front panel 104 and the back panel 106. Overlapping sideseams may have favorable characteristics with respect to shear strength(in the plane of the front and back panels) and may be configured to beeasily torn apart when removing an article from the wearer. FIGS. 2 and2 a show the absorbent article 100 having side seams 122, 124 in theform of outwardly located butt-type seams 130, 132. The butt-type seams130, 132 are formed by folding the pre-form 118, along the transversecenter line 124 and superimposing sealing areas that are located onwearer facing surfaces of the blank in a face-to-face relationship. Asshown in FIGS. 2 and 2 a, sealing lines 134 of the butt-type seams 130,132 may be located inboard from the outer periphery, leaving outermostedges of the seam unattached to help create a relatively soft edge. Itshould be appreciated that the butt-type side seams 130, 132 may beinwardly oriented, or located on the inside of the absorbent article100.

It is to be appreciated that overlapping seams 126, 128 and butt-typeseams 130, 132 may be formed with various types of connection methods,including for example, pressure bonding, ultrasonic bonding, heatsealing, adhesive attachment, and mechanical attachment. Adhesive andmechanical attachments may include, for example, patches of hook-typeand loop-type material. Such patches may be located parallel to thesides seams and may be located perpendicular to the seams. The sideseams 122, 124 may be joined by adhesive tape extending perpendicularlyto the seams. The sealing mechanism or adhesive tape may provide for aresealable side seam and may be attached by the manufacturer to form theabsorbent article 100. After the absorbent article 100 has been attachedon a wearer, the side seams 122, 124 can be unfastened for inspection ofthe inside of the article and can after inspection be re-closed by theuser for further use.

As mentioned above, absorbent articles 100 having side seams 122, 124may be formed from a blank 118 during the manufacturing process. For thepurposes of a specific illustration, FIGS. 3 and 4 show an example blank118 that may be used to form an absorbent article 100 having side seams122, 124. In general, the blank 118 shown in FIG. 3 is a representationof the absorbent articles 100 of FIGS. 1 and 2 in the form of diapers102 prior to joining of the front panel 104 and the rear panel 106. Assuch, the blank 118 shown in FIG. 3 along may be folded along thetransverse center line 120 and the back panel 106 and the front panel104 connected with overlapping seams 126, 128 or butt-type seams 130,132 as shown in FIGS. 1 and 2.

FIG. 3 is a plan view of the blank 118 including a chassis 136 shown ina flat, unfolded condition, with the portion of the chassis that facestoward a wearer oriented towards the viewer. FIG. 4 shows across-sectional view of the blank 17 shown in FIG. 3. To provide a frameof reference for the present discussion, the chassis 136 is shown with alongitudinal axis 138 and a lateral axis 140. As shown in the FIG. 3,the lateral axis 140 may correspond with the transverse center line 120.The chassis 136 is shown as having a first waist region 142, 142′; asecond waist region 144, 144′; and a crotch region 146, 146′ disposedintermediate the first and second waist regions. The periphery of thediaper is defined by a pair of longitudinally extending side edges 148,150; a first outer edge 149 extending laterally adjacent the first waistregion 142; and a second outer edge 151 extending laterally adjacent thesecond waist region 144. A length, L_(BLANK), of the blank is defined bya longitudinal distance between the first outer edge 149 and secondouter edge 151. A length, L_(BLANK), defined by relatively largeabsorbent articles may be longer than a length, L_(BLANK), defined byrelatively small absorbent articles.

Still referring to FIG. 3, the longitudinal edges 148, 150 extendgenerally in the direction of the longitudinal center line 138 and maycurve to define cut-out regions that form portions of the leg openings108, 110 of the absorbent article 100. The chassis 136 may also includean outer covering layer 152 including a topsheet 154 and a backsheet156, and an absorbent core 158 disposed between a portion of thetopsheet and the backsheet. It is to be appreciated that any one or moreof the regions of the chassis may be stretchable and may include varioustypes of elastomeric materials and/or laminates. As such, the diaper 102may be configured to adapt to a specific wearer's anatomy uponapplication and to maintain coordination with the wearer's anatomyduring wear. The blank 118 may further comprise waist elastics 160, 162and leg elastics 164, 166. As shown in FIGS. 3 and 4, the longitudinaledges 148, 150 adjacent the first waist region 142, 142′ and the secondwaist region 144, 144′ include sealing areas 168, 170, 172, 174, whichmay comprise a thermoplastic material. In addition, a gripping area 176,178, 180, 182 may be provided adjacent each sealing area 168, 170, 172,174. The gripping and sealing areas are discussed in more detail belowin the context of describing the operation of embodiments of theprocessing wheels.

As discussed above, the absorbent article may include an absorbent core158, which may comprise any absorbent material capable of absorbing andretaining liquids such as urine and other body exudates. Exemplary butnot limiting absorbent structures for use as the absorbent core 158 aredescribed in U.S. Pat. Nos. 4,610,678, 4,673,402, 4,888,231, and4,834,735, each herein incorporated by reference. The absorbent core 158may be manufactured in a wide variety of sizes and shapes (e.g.,rectangular, hourglass, “T”-shaped, asymmetric, etc.), and from a widevariety of liquid-absorbent materials commonly used in disposablediapers and other absorbent articles. The absorbent core may alsoinclude multiple layers of absorbent material, each having individualliquid acquisition, acquisition/distribution, or storage/redistributioncharacteristics, as well as individual shape, width, length, andthickness characteristics. The number and placement of absorbent layersmay be varied to achieve desired characteristics such as thinness,softness, flexibility, or beneficial liquid acquisition, distribution,and storage rates, as well as capacity and storage rates, wearercomfort, etc. The components or members of the absorbent core mayinclude laminates or combinations of several sheets or webs ofmaterials. In general, the absorbent core may be made of any suitableabsorbent material or combination of materials.

As shown in FIG. 4, the backsheet 156 may be positioned adjacent agarment facing surface of the absorbent core 158 and may be joinedthereto in any suitable manner, including but not limited to adhesive,heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds,or any other suitable attachment. See, e.g., U.S. Pat. Nos. 4,573,986and 4,842,666, each herein incorporated by reference. Some portion orall of the backsheet 156 may be generally impervious to liquids (e.g.,urine) and may be manufactured from a thin plastic film, although otherflexible liquid impervious materials may also be used. The backsheet 156may thus comprise a woven or nonwoven material, polymeric films such asthermoplastic films of polyethylene or polypropylene, compositematerials such as a film-coated nonwoven material, or any other suitablematerial. The backsheet 156 may be embossed and/or matte finished toprovide a more cloth-like appearance. Further, the backsheet 156 maypermit vapors to escape from the absorbent core 158 (i.e., breathable)while preventing exudates from passing through the backsheet 156.

As shown in FIG. 4, the topsheet 154 is positioned adjacent a bodyfacing surface of the absorbent core 158 and may be joined theretoand/or to the backsheet 156. Suitable attachment methods are describedwith respect to joining the backsheet 156 to the absorbent core 158. Thetopsheet 154 may be compliant, soft feeling, and non-irritating to thewearer's skin. Generally, the topsheet 154 may be liquid perviouspermitting liquids (e.g., urine) to readily penetrate through itsthickness. A topsheet can be manufactured from a wide range of materialssuch as woven and nonwoven materials; polymeric materials such asapertured formed thermoplastic films, apertured plastic films, andhydroformed thermoplastic films; porous foams; reticulated foams;reticulated thermoplastic films; and thermoplastic scrims. Example wovenand nonwoven materials can include natural fibers, e.g., wood or cottonfibers, synthetic fibers, e.g., polymeric fibers such as polyester,polypropylene, or polyethylene fibers, or a combination of natural andsynthetic fibers. In one embodiment, the topsheet is made of ahydrophobic material to isolate the wearer's skin from liquids containedin the absorbent core that is treated on at least one side with asurfactant to allow liquids to readily penetrate therethrough. High loftnonwoven topsheets and apertured formed film topsheets may be used.Apertured formed films are pervious to bodily liquids, non-absorbent,and have a reduced tendency to allow liquids to pass through in adirection away from the absorbent core and thereby rewet the wearer'sskin. Thus, the surface of the formed film that is in contact with thebody remains dry, thereby reducing bodily soiling and creating a morecomfortable feel for the wearer. The body-facing surface of the formedfilm topsheet can be hydrophilic, thereby helping bodily liquidstransfer through the topsheet faster and diminishing the likelihood thatliquid will flow off the topsheet rather than flowing into and beingabsorbed by the absorbent core. There are a number of manufacturingtechniques that may be used to manufacture the topsheet 154. Forexample, the topsheet 154 may be a nonwoven web of fibers spunbonded,carded, wet-laid, meltblown, hydroentangled, thermally bonded,combinations of the above, or the like.

In some embodiments, an absorbent core structure without a topsheet maybe used to provide desirable results, such as comfort and absorbency, aswell as simplicity in manufacturing and material cost savings. Forexample, the body facing surface of the absorbent core may be made ofliquid pervious, soft, compliant, non-irritating materials. Such anabsorbent core may be used in combination with a backsheet to providethe desired comfort and absorbency in an absorbent article.

In some embodiments, the topsheet 154 and the backsheet 156 arecoextensive and have length and width dimensions generally larger thanthose of the absorbent core 158. In other embodiments, the topsheet 154may be slightly smaller than the backsheet 156. The size of thebacksheet and/or topsheet may be guided by the size of the absorbentcore and the article design selected.

As mentioned above, elastics, including waist elastics and leg elasticsmay be provided to exert a contracting force on the absorbent article sothat the absorbent article configures more closely and more comfortablyto the wearer. Elastic members for use in wait elastics and leg elasticscan be assembled in a variety of well known configurations, such asthose described generally in U.S. Pat. No. 3,860,003, hereinincorporated by reference.

As shown in FIGS. 1-3, the disposable absorbent article 100 may compriseelasticized leg cuffs 164, 166 for providing improved containment ofliquids and other body exudates. Each elasticized leg cuff may compriseseveral different embodiments for reducing the leakage of body exudatesin the leg regions. The leg cuff can be and is sometimes also referredto as leg bands, side flaps, barrier cuffs, or elastic cuffs. Variouscuffs, flaps, and openings are described in U.S. Pat. Nos. 3,860,003,4,909,803, and 4,695,278, each of which is herein incorporated byreference.

As shown in FIGS. 1-3, the disposable absorbent article may comprise anelastic waist feature 160, 162 that provides improved fit andcontainment. The elastic waist feature is that portion or zone of theabsorbent article which is intended to elastically expand and contractto dynamically fit the wearer's waist. The elastic waist feature mayextend longitudinally outwardly from at least one of the waist edges ofthe absorbent core 158 and may generally form at least a portion of theend edges of the blank 118. Thus, waist elastics 160, 162 may bedisposed adjacent either or both transverse edges 149, 151 to provide awaistband. Disposable absorbent articles may be constructed so as tohave two elastic waist features 160, 162. For example, one elastic waistfeature 149 may be positioned in the first waist region 142, 142′ andone elastic waist feature 151 may be positioned in the second waistregion 144, 144′. It should also be appreciated that diapers can beconstructed with a single elastic waist feature. The waist elastics 160,162 may be secured to the absorbent article in an elasticallycontractible condition so that, in a normally unrestrainedconfiguration, the waist elastics effectively contract or gather theabsorbent article. The elastics 160, 162 may also extend less than orequal the entire length of the transverse edges 149, 151 to provide anelastically contractible line. In one embodiment illustrated in U.S.Pat. No. 4,515,595, elastic waist elements extend across essentially theentire lateral width of a disposable diaper. Similar waistbands may beuseful in designs wherein the elastic waist elements extend across onlya portion of the lateral width of an absorbent article. While theelastic waist feature or any constituent elements can comprise aseparate element affixed to the absorbent article, the elastic waistfeature may be constructed as an extension of other elements of thediaper such as the backsheet 156 or the topsheet 154, or both thebacksheet 156 and the topsheet 154. The elastic waistband may also beconstructed in a number of different configurations including thosedescribed in U.S. Pat. Nos. 4,515,595 and 5,151,092, each incorporatedherein by reference.

FIGS. 4 a-4 e illustrate different embodiments of blanks 118 that may beused with the disclosed methods and apparatuses. In particular, FIGS. 4a-4 e show cross-sectional views along a cross-section that extendsparallel to lateral axes of the blanks 118 and that cuts through twosealing areas 140, 142. The two sealing areas 140, 142 may correspondwith the locations of the waist sealing areas 168, 170 or 172, 174 shownin FIGS. 3 and 4 or may be located in other areas. FIG. 4 a shows anembodiment wherein the blank 118 from which the absorbent article 100 isformed comprises a topsheet 154, a backsheet 156, and a core 158interposed between the topsheet and backsheet. The backsheet is formedby a thermoplastic film 156′ and a non-woven outer layer 156″. Thethermoplastic film 156′ is not coterminous with the non-woven outerlayer 156″, such that in each sealing area 140, 142 only two layers ofthe non-woven material 156″ are present. The absorbent structure mayalso be made breathable through the use of regions of the non-wovenmaterial that are not covered by impermeable film 156′. In theembodiment of FIG. 4 b, the blank 118 includes a thermoplastic filmbacksheet 156, 156′ having panels of stretchable material attachedthereto that form elasticized stand-up cuffs 188, 190 provided on eachside of the core 158. In the embodiment of FIG. 4 c, the blank 118includes a reusable holder for absorbent insert cores. As such, theblank 118 includes a non-woven backsheet 156, 156″ and twopocket-forming flaps 192, 194 between which a disposable insert core canbe inserted, wherein the flaps 192, 194 help to hold the disposableinsert core in position. FIG. 4 d shows a blank 118 with a backsheet156, which may include a laminate of two non-woven layers 156″, 156″,wherein both nonwoven layers extend into the sealing areas 184, 186 forimproved strength of the side seams. It should be appreciated that theblank in FIG. 4 d could also include a backsheet comprising a laminateof a nonwoven layer and a thermoplastic layer, or the backsheet could beany other suitable material or materials. FIG. 4 e shows a blank 118wherein both the topsheet 154 and the backsheet 156 extend into thesealing areas 184, 186 to form reinforced side seams.

Various types of articles, such as those discussed above with referenceto FIGS. 1-4 e, may be produced in accordance with the methods andapparatuses disclosed herein. In some embodiments, a continuous web maybe cut into individual blanks, and the individual blanks are transferredto a processing wheel. More particularly, the individual blanks aretransferred to corresponding processing stations moving along an orbitpath as the processing wheel rotates. As the processing stations movealong an orbit path, the processing stations may perform variousoperations, such as folding the blanks, superimposing sealing areas onthe folded blanks, and sealing the side seams to form individualabsorbent articles.

FIG. 5 illustrates a schematic view of an example process for formingabsorbent articles having side seams. As shown in FIG. 5, a continuousweb 200 from which individual blanks 118 will be formed moves in amachine direction (MD) along a conveyor 202 from an upstream convertingprocess wherein various absorbent article components may be combinedwith one or more advancing substrates of material. From the conveyor,the web 200 is transferred to a cutting station 204 that includes afinal knife roll 204 and an anvil roll 206. The cutting station performsa final knife cut on continuous web 200, which separates the continuousweb into individual blanks 118, such as shown in FIG. 3. The final knifecut separates the continuous web between a trailing edge of one blankand the leading edge of another blank. It is to be appreciated thatvarious embodiments of cutting stations can be used other than thoseshown in FIG. 5. After the final knife cut, the individual blanks aretransferred to a rotating processing wheel 210. As discussed in moredetail below, the individual blanks 118 are transferred from the kniferoll to individual processing stations 212 on the processing wheel 210at a receiving location 214.

With reference to FIG. 5, as the processing wheel rotates 210, theprocessing stations 212 operate to perform various operations, such asfolding and sealing the individual blanks 118. As shown in FIG. 5, asthe processing wheel rotates, the individual processing stations 212move from the receiving location 214 to a folding location, which isgenerally represented by an arc 216. As discussed in more detail below,as the processing stations move along the folding location 216, theprocessing stations 212 actuate and fold the individual blanks 118 alongone or more lateral axes 140, as discussed above with reference to FIGS.1-3. As discussed in more detail below, the processing stations 212 mayfold the blanks 118 in more than one direction, such as along one ormore transverse axes 140 to form a U-shape of the absorbent article 100and along the gripping areas 176, 178, 180, 182 to position the sealingareas 168, 170, 172, 174 for engagement.

As the processing wheel continues to rotate, the processing stations 212move from the folding location 216 to a sealing location, generallyrepresented in FIG. 5 by an arc 218. As the processing stations movealong the sealing location 218, the processing stations engage thesealing areas 168, 170, 172, 174 on the blanks 118 to form side seams122, 124 of absorbent articles 100, such as discussed above withreference to FIGS. 1-4 e. The processing wheel 210 continues to rotateand the processing stations 212 move from the sealing location 218 to adischarge location 220, where the folded absorbent articles 100 areremoved from the processing wheel 210. As the processing stations 212move along the sealing location, the side seams are formed. As discussedabove, the side seams may be formed with various types of connectionmethods, including for example, pressure bonding, ultrasonic bonding,heat sealing, adhesive attachment, and mechanical attachment. As such,in some arrangements, such as when forming absorbent articles withresealable side seams utilizing, for example, adhesives or mechanicalattachments, pressure may be applied to the sealing area to form theside seams. In other arrangements, a heat exchanger and a compressiontool may be used to form the side seams. In some embodiments, the heatexchanger forces hot air against the folded blanks, and the compressiontool presses the side seams. In some embodiments, cool air may also beapplied to the folded, seamed blanks to cool the blanks duringcompression. It is to be appreciated that depending on the particularconfiguration, heating and cooling times for the side seam material mayvary. It should also be appreciated that FIG. 5 is schematicrepresentation of an embodiment, and the positions and durations of someprocess steps may vary and/or may overlap, such as the receiving,folding, sealing, and discharge locations.

As previously mentioned, the processing wheel includes a plurality ofprocessing stations. For example, the processing wheel 210 shown in FIG.5 includes nine processing stations 212. It should be appreciated thatthe processing wheel may include more or less processing stations thanillustrated herein. For example, some embodiments may include sixprocessing stations and some embodiments may include twelve processingstations. As discussed above, the processing stations 212 performvarious operations as the processing wheel rotates. For example,individual blanks 118 disposed on respective processing stations 212 arefolded as the processing wheel rotates. As such, each processing station212 may include a folding mechanism upon which an individual blank isdisposed as the processing wheel rotates. One embodiment of a foldingmechanism 222 is shown in FIGS. 6 a-6 d. In particular, FIG. 6 a shows adetailed view of the folding mechanism 222 on the processing wheel, FIG.6 b shows a top view of the folding mechanism 222; FIG. 6 c shows across sectional view of the folding mechanism and processing wheel shownin FIG. 6 a taken along line I-I; and FIG. 6 d shows a cross sectionalview of the folding mechanism and processing wheel shown in FIG. 6 ctaken along line II-II.

As shown in FIGS. 6 a and 6 b, the folding mechanism 222 includesgripper members 224, 226, 228, 230 which hold the blank 118 while theprocess wheel 210 rotates. More particularly, with reference to FIGS.3-6 d, the individual blanks 118 are transferred from the final stationto the holding mechanism such that the grippers member 224, 226, 228,230 are brought into contact with four respective gripping areas 176,178, 180, 182 on the blanks 118. Each gripper may be configured with avacuum that exerts a holding force on a respective gripping area of theblank. The gripper members are configured to rotate and move to fold theblanks 118.

As shown in FIGS. 6 b and 6 d, the folding mechanism 222 also includescarrier arms 232, 234, 236, 238 that rotatably support the grippermembers 224, 226, 228, 230. As such, the gripper members are adapted torotate about gripper axes 240, 242, 244, 246 at a distal end portion ofthe carrier arms. Proximal end portions of the carrier arms 232, 234,236, 238 are pivotally connected to a distal end portion 248 of a firstfollower member 250. As such, the carrier arms 232, 234, 236, 238 areadapted to pivot about hinge axes 252, 254. From the distal end portion248, the first follower member 250 extends through a hub member 256 to aproximal end portion 258. As such, the first follower member 250 isslidably connected with the hub member 256 and can move relative to thehub in directions “A” and “B” shown in FIG. 6 d. The proximal endportion the first follower member 250 is operably connected with a firsttrack 260 through one or more first rollers 262. As shown in FIGS. 6 cand 6 d, the first track 260 is stationary, and the hub member 256 isconnected with and rotates with the processing wheel 210 along a pathradially outward of the first track 260. Thus, as the processing wheel210 rotates, the first track 260 remains stationary, the hub member 256moves in a circular path about a rotation axis 264, and the firstrollers roll 262 along the first track 260. As discussed in more detailbelow, depending on the path defined by the first track 260, the firstfollower member 250 may move radially inward and/or outward in directionA relative to the hub member 256 as the hub member moves in the circularpath around the rotation axis 264.

As shown in FIGS. 6 b and 6 d, the folding mechanism 222 also includes asecond follower member 266 that is operably connected with the firstfollower member 250 to pivot the carrier arms 232, 234, 236, 238 aboutthe hinge axes 252, 254 as the processing wheel 210 rotates. Moreparticularly, a distal end portion 268 of the second follower 266 memberis pivotally connected with first end portions of connecting arms 270,272. In turn, a second end portion of connecting arm 270 is pivotallyconnected with carrier arms 232, 234, and a second end portion ofconnecting arm 272 is pivotally connected with carrier arms 236, 238.Distance control arms 271, 273 may also be provided. Opposing endportions of the distance control arms 271, 273 may be pivotallyconnected with the first follower member 250 and the connecting arms270, 272.

From the distal end portion 268, the second follower member 266 extendsthrough a hollow interior of the first follower member 250 and the hubmember 256 to a proximal end portion 274. As such, the second followermember 266 is telescopically connected with the first follower member250 and can move relative to the first follower member in the directionsA and B shown in FIG. 6 d. The proximal end portion 274 the secondfollower member 268 is operably connected with a second track 276through one or more second rollers 278. As shown in FIG. 6 d, the secondtrack 276 is stationary and defines a path radially inward of the firsttrack 260. The hub member 256 is connected with and rotates with theprocessing wheel 210 radially outward of the second track 276. Thus, asthe processing wheel 210 rotates, the second track 276 remainsstationary, the hub member 256 moves in a circular path about therotation axis 264, and the second rollers 278 roll along the secondtrack 276. As discussed in more detail below, depending on a pathdefined by the second track 276 relative to the first track 260, thesecond follower member 266 may move radially inward and/or outwardrelative to the first follower member 250 as the hub member 256 moves inthe circular path around the rotation axis 264. As such, movement of thesecond follower member 266 in a radially outward direction A relative tothe first follower member 250 causes the second follower member 266 andconnecting arms 270, 272 to push the carrier arms 232, 234, 236, 238 topivot in direction C shown in FIG. 6 e toward an extended position. FIG.6 e shows the folding mechanism 222 in an extended position. Incontrast, movement of the second follower member 266 in a radiallyinward direction B relative to the first follower member 250 causes thesecond follower member 266 and connecting arms 270, 272 to pull thecarrier arms to pivot in direction shown in FIG. 6 f toward a retractedposition or folding position. FIG. 6 f shows the folding mechanism 222in a retracted position or folding position.

It is to be appreciated the first and/or second follower members can beconfigured with only one roller and may also have various types ofcomponents other than rollers. For example, some embodiments may beconfigured various types of rolling contact elements, such as forexample, ball bearings. Other embodiments may include pins that movealong slotted tracks. In yet other embodiments, the follower members mayconfigured with slots or voids that are adapted to receive and movealong a protruding track.

As discussed above with reference to FIGS. 6 a-6 d, the gripper members224, 226, 228, 230 are adapted to move and to fold the individual blanks118 as the processing wheel 210 rotates. As previously described, thegripper members 224, 226, 228, 230 may be rotatably mounted on carrierarms 232, 234, 236, 238, and are adapted to be rotated about gripperaxes 240, 242, 244, 246. The carrier arms 232, 234, 236, 238, in turn,are connected to first follower member 250 and can each be rotatedaround the hinge axes 252, 254. The hinge axes 250, 252 extend generallyperpendicular to the rotational travel of the processing wheel 210 andgenerally perpendicular to the carrier arms 232, 234, 236, 238. Foldingof the blank 118 occurs at the folding area 216 of the processing wheel210, as indicated in FIG. 5. Folding of the blank 118 may occur in twodirections: (1) along one or more transverse axes 140 to form a U-shapeof the absorbent article 100; and (2) along the gripping areas 176, 178,180, 182 to position the sealing areas 168, 170, 172, 174 forengagement. In some configurations, the gripper members may be rotatablyconnected with the carrier arms through a helical or barrel camarrangement that allows the gripper members to move linearly along thelength of the carrier arms as the carrier arms pivot. Such movementallows the gripper members to maintain a relatively constant position ofthe grippers on the blank as the blank is folded while at the same timeavoiding the stretching of the blank.

As shown in FIGS. 6 b and 6 c, the first follower member 250 includesanvils 280, 282 on opposing sides of the distal end portion 248 of thefirst follower member. In addition, seaming heads 284, 286 are mountedon the processing wheel adjacent the anvils 280, 282. More particularly,the seaming heads 284, 286 are connected with support arms 288, 290 thatare pivotally connected with the processing wheel 210. As the processingwheel rotates through the folding location 218, the support arms 288,290 pivot to place the seaming heads 284, 286 in close proximity to theanvils 280, 282 while the sealing operation is carried out. As theprocessing wheel continues to rotate, the support arms 288, 290 pivot inan opposite direction to move the seaming heads 284, 286 away from theanvils 284, 286. The movement of the support arms and seaming heads canbe accomplished in various ways. For example, in one embodiment, thesupport arms engage a cam surface that causes the carrier arms to pivota particular distance and for a particular portion of the processingwheel's rotation.

FIG. 6 b shows an individual blank disposed on a folding mechanism 222an extended position. As such, the gripping areas 176, 178, 180, 182 ofthe blank are disposed on respective gripper members 224, 226, 228, 230.As the processing wheel 210 rotates through the folding location 216shown in FIG. 5, the folding mechanism 222 retracts to the foldingposition by pivoting the carrier arms 232, 234, 236, 238 about the hingeaxes 252, 254 in direction D shown in FIG. 6 f. In addition, eachgripper member 224, 226, 228, 230 may rotate about the gripper axes 240,242, 244, 246 to place the sealing areas 168, 174 and 170, 172 of theblank 118 an overlapping relationship. As the processing wheel 210rotates from the folding location 216 into the sealing location 218, theoverlapped sealing areas 168, 174 and 170, 172 are located adjacentanvils 280, 282 on the first follower member 250. Seaming heads 284, 286then move to press the overlapped sealing areas 168, 174 and 170, 172against each other between the anvils 280, 282 and the seaming heads284, 286, which in turn, seal the overlapped sealing areas 168, 174 and170, 172 with one another. As the processing wheel 210 continues throughthe sealing location, the seaming heads 284, 286 retract and move awayfrom the overlapped sealing areas 168, 174 and 170, 172, having createdoverlapping side seams 126, 128 of an absorbent article 100 as shown forexample in FIGS. 1 and 1 a.

It should be appreciated that the folding station 222 can also beconfigured to create butt-type seams 130, 132 such as shown in FIGS. 2and 2 a. Thus, instead of overlapping the sealing areas 168, 174 and170, 172, the gripper members 224, 226, 228, 230 may be simultaneouslyrotated around the respective gripper axes 240, 242, 244, 246 such thatthe sealing areas 168, 174 and 170, 172 mutually abut and extendgenerally perpendicular outward from the first follower member 250.Sealing may then occur by pressing the abutting sealing areas 168, 174and 170, 172 between two seaming heads. For example, FIG. 7 a shows twoseaming heads 284, 284′ pressing sealing areas 168, 174 together in anabutting relationship.

Depending on the configuration of the folding station 222 and associatedparts, different embodiments of overlapping and abutting side seams canbe created, such as for example, shown in FIGS. 7 b and 7 c. In theembodiment of FIG. 7 b, a side seam is formed as a combination of abutt-type seam such as shown in FIG. 2 and an overlapping seam such asshown in FIG. 1. The seam of FIG. 7 b can be formed by first placing thesealing areas 168, 174 in an abutting relationship as shown in FIG. 7 a,and then folding over the abutting sealing areas. The folded-overabutting sealing areas 168, 174 may then be compressed between theseaming head 284 and the anvil 280. FIG. 7 c shows an overlapping seamcomprising three layers of material. In this embodiment, the sealingarea 168 is folded over before being placed in a superimposedrelationship with the sealing area 174.

It is to be appreciated that various types and configurations of seamingheads and anvils may be used to create the side seams on the absorbentarticles. As discussed above, the side seams may be formed with varioustypes of connection methods, including for example, pressure bonding,ultrasonic bonding, heat sealing, adhesive attachment, and mechanicalattachment. As such, in some arrangements, such as when formingabsorbent articles with resealable side seams utilizing, for example,adhesives or mechanical attachments, the seaming heads may act only toapply pressure to the sealing areas to form the side seams. In anotherexample, the seaming heads may comprise heated elements that contact theanvils under any pressure. In some embodiments, the pressure may be inthe range of from about 1 psi to about 10⁴ psi. In other embodiments,side seaming may utilize with hot air. In one example, a heat exchangeris brought close to overlapping material of the blank and blows hot airagainst the blank. After applying the hot air, seaming heads compressthe overlapping sides. Thus, the material of the side portions is heatedand compressed to form the side seal. In yet another embodiment, theseaming heads comprise an ultrasonic conductor. The ultrasonic energyimparted to the sealing areas puts the thermoplastic material of thesealing areas in a heat-softened state, such that upon compression ofthe sealing areas between the anvil and the conductors an overlappingside seam is formed.

Although the above discussion presents a detailed discussion ofembodiments of the processing and folding stations, it is to beappreciated that other embodiments of processing stations that may beadapted for use with the methods and apparatuses disclosed herein. Forexample, U.S. Pat. No. 7,322,925, U.S. Pat. No. 5,779,831, and U.S.Patent Publication No. 2008083489A1 provide descriptions of variousembodiments of processing and folding stations that can be adapted foruse with the methods and apparatuses disclosed herein.

As shown in FIG. 6 b, the folding mechanism 222 defines a length,L_(STATION), between distal end portions of the gripper members 224,226, 228, 230. The length, L_(STATION), corresponds with the length,L_(BLANK), of the blanks 118 discussed above with reference to FIG. 3.As such, the geometry of the processing stations 212 and foldingmechanisms 222 may be adapted to accommodate the length of the blanks118 being manufactured. For example, a length, L_(BLANK), defined byrelatively large absorbent articles may require the folding mechanism todefine a corresponding length, L_(STATION), that is relatively long. Inanother example, a length, L_(BLANK), defined by relatively smallabsorbent articles may require the folding mechanism to define acorresponding length, L_(STATION), that is relatively short. Thus,depending upon the length of the blanks to be manufactured, the foldingmechanisms on the processing wheel may be changed to define shorter orlonger lengths, L_(STATION). In turn, the first track 260 and/or secondtrack 276 may be changed to define different shapes to accommodate thechanged geometry of the folding stations.

In one example, FIG. 8 a shows a schematic representation of aprocessing wheel 210 and folding stations 212 configured for themanufacture of relatively small blanks 118 (i.e. relatively shortL_(BLANK)). As the processing wheel rotates around the rotation axis264, the processing stations 212 and folding mechanisms 222 move fromthe receiving location 214, through the folding location 216 and thesealing location 218, to the discharge location 220, and around to thereceiving location 214. Thus, the distal end portion 248 of the firstfollower member 250 travels along an orbit path 292 shown in FIG. 8 b.As discussed above, during rotations of the processing wheel 210, thefirst rollers 262 roll along the first track 222. As such, radial inwardand outward movements of the folding mechanisms 222 relative to rotationaxis 264 are dictated by the circumferential shape of the first track260. As shown in FIG. 8 a, the first track 260 defines a circularcircumferential shape. Thus, as the distal end portions 248 of the firstfollower members 250 travel along a circular-shaped orbit path 292having a constant distance R_(SMALL) from the rotation axis 264.

FIGS. 9 a and 9 b illustrate an example of how the processing wheel 210can be reconfigured to accommodate relatively larger blanks 118 ascompared to the processing wheel configuration of FIGS. 8 a and 8 b. Inparticular, FIG. 9 a shows a schematic representation of a processingwheel 210 and folding stations 212 configured for the manufacture ofrelatively large blanks 118 (i.e. relatively long L_(BLANK)). Again, asthe processing wheel rotates around the rotation axis 264, theprocessing stations 212 and folding mechanisms 222 move from thereceiving location 214, through the folding location 216 and the sealinglocation 218, to the discharge location 220, and around to the receivinglocation 214. Thus, the distal end portion 248 of the first followermember 250 travels along orbit path 292 shown in FIG. 9 b. As discussedabove, during rotations of the processing wheel 210, the first rollers262 roll along the first track 222. As such, radial inward and outwardmovements of the folding mechanisms 222 relative to rotation axis 264are dictated by the circumferential shape of the first track 260. Thus,as the distal end portions 248 of the first follower members 250 travelalong a circular-shaped orbit path 292 having a variable distanceR_(LARGE) from the rotation axis 264. However, the circumferential shapeof the first track 260 shown in FIG. 9 a is different than the firsttrack shown in FIG. 8 a. More particularly, the first track 260 in FIG.9 a is shaped such that the distal end portions 248 of the firstfollower members 250 move radially outward from the rotation axis 264 asthe folding stations move past the discharge location 214 and untilmoving into the sealing location 218. Once the folding stations 222 moveinto sealing location 218, the distal end portions 248 of the firstfollower members 250 move inward toward the rotation axis 264 untilafter the discharge location 220. Thus, the distal end portion 248 ofthe first follower member 250 travels along an orbit path 292 shown inFIG. 9 b.

As previously mentioned, the apparatuses and methods according to thepresent disclosure provide flexibility in reconfiguring the processingwheel to fold and seam different sizes of absorbent articles. Forexample, the processing wheel configuration shown in FIG. 9 a allows thefolding mechanisms 222 to be geometrically modified to have relativelylonger L_(STATION) without having to make corresponding modifications toother equipment and operations associated with the processing wheel 210.For instance, the shape of the first track 260 causes the distal endportions 248 of the first follower members 250 to move outwardly fromthe rotation axis 264 while the folding mechanisms 222 are in anextended position, such as shown in FIG. 6 e. The outward movement ofthe distal end portions 248 allow folding mechanisms 222 having arelatively long L_(STATION) dimensions to move to extended positionswithout interfering with adjacent folding mechanisms 222. In contrast,once the folding mechanisms 222 move to retracted positions, such asshown in FIG. 6 f, the shape of the first track 260 causes the distalend portions 248 of the first follower members 250 to move inwardlytoward the rotation axis 264. The shape of the first track 262 can beconfigured such that the first follower members 250 are moved to thesame radial position relative to the rotation axis 264 in FIG. 9 aduring the sealing operation as in FIG. 8 a. As such, the geometry ofthe folding mechanisms 222 can be adjusted to accommodate differentsized blanks 118 without having to remove, reinstall, and realign thevarious parts, such as the anvils 280, 282 and/or sealers 284, 286.

In another example, comparing FIGS. 8 a and 9 a, the first track 260defines a shape that allows the folding stations 222 to accommodatedifferent sized blanks 118 without having to move the discharge location220 closer to or farther away from the rotation axis 264 of theprocessing wheel 210. For example, as shown in FIGS. 8 a and 9 a, blanks118 are discharged from the processing wheel 210 to another mechanism,in the form of a vacuum roller 294, at the discharge location 220. Thefolding stations 222 can be geometrically modified to accommodatedifferent sized blanks 118 without having to physically move and realignthe vacuum roller 294 with the processing wheel 210. It should also beappreciated that the first track 260 can be configured in differentshapes than what are shown and described herein. For example, the firsttrack 260 can be modified to define an orbit path 292 having straightportions. In one embodiment, the orbit path is configured with astraight portion near the discharge location 220 when discharging theblanks 118 onto a flat conveyor, as opposed to a vacuum roll. In otherexamples, the first track 260 can be configured to define an orbit path292 wherein the distal end portions 248 of the first follower members250 move radially outward from the rotation axis 264 when transitioningfrom the folding location 216 to the sealing location 218.

As previously discussed, it is to be appreciated that other embodimentsof processing stations that may be adapted for use with the methods andapparatuses disclosed herein, such as disclosed for example in U.S. Pat.No. 7,322,925, U.S. Pat. No. 5,779,831, and U.S. Patent Publication No.2008083489A1. As such, it is contemplated that other processing stationconfigurations may utilize folding mechanisms that are actuated invarious ways without utilizing relative positions between first andsecond tracks as discussed above.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”Every document cited herein, including any crossreferenced or related patent or application, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An apparatus for making absorbent articles having side seams, theapparatus comprising: a wheel adapted to rotate about a rotation axis; afirst track defining a first circumferential shape surrounding therotation axis, wherein the first track is stationary relative to thewheel; a second track defining a second circumferential shapesurrounding the rotation axis, wherein the second track is stationaryrelative to the wheel; a plurality of folding mechanisms disposed on thewheel, each folding mechanism comprising: a first follower membermovably connected with the first track, the first follower member havinga proximal end portion and a distal end portion; a carrier arm pivotallyconnected with the first follower member; a gripper member connectedwith the carrier arm; a second follower member connected with thecarrier arm and movably connected with the second track; and wherein asthe wheel rotates, the distal end portion of the first follower memberorbits in a first orbit path about the rotation axis in correspondencewith the first circumferential shape; and wherein as the wheel rotates,the second follower member moves relative to the first follower memberin correspondence with a relative radial distance between the firsttrack and the second track.
 2. The apparatus of claim 1, wherein thefirst orbit path is defined by a varying distance from rotation axis. 3.The apparatus of claim 1, wherein the first orbit path is partiallydefined by a curved portion and a straight portion.
 4. The apparatus ofclaim 1, further comprising a first roller connected with the proximalend portion of the first follower member, and wherein the first rolleris rollingly engaged with the first track.
 5. The apparatus of claim 4,further comprising a second roller connected with a proximal end portionof the second follower member, and wherein the second roller isrollingly engaged with the second track.
 6. The apparatus of claim 1,further comprising a seamer member adapted to periodically engage thefirst follower member as the wheel rotates.
 7. An apparatus for makingabsorbent articles having side seams, the apparatus comprising: a wheeladapted to rotate about a rotation axis; a first track defining a firstcircumferential shape surrounding the rotation axis, wherein the firsttrack is stationary relative to the wheel; a plurality of foldingmechanisms disposed on the wheel, each folding mechanism comprising: afirst follower member movably connected with the first track, the firstfollower member having a proximal end portion and a distal end portion;a carrier arm pivotally connected with the first follower member; agripper member connected with the carrier arm; wherein as the wheelrotates, the carrier arm is selectively pivoted relative to the firstfollower member; and wherein as the wheel rotates, the distal endportion of the first follower member orbits in a first orbit path aboutthe rotation axis in correspondence with the first circumferentialshape, wherein the first orbit path is defined a varying distance fromthe rotation axis.
 8. The apparatus of claim 7, further comprising: asecond track defining a second circumferential shape surrounding therotation axis; a second follower member connected with the carrier armand movably connected with the second track.
 9. The apparatus of claim8, wherein the second follower member moves relative to the firstfollower member in correspondence with a relative radial distancebetween the first track and the second track.
 10. The apparatus of claim7, wherein the first orbit path comprises a curved portion and astraight portion.
 11. The apparatus of claim 7, further comprising afirst roller connected with the proximal end portion of the firstfollower member, and wherein the first roller is rollingly engaged withthe first track.
 12. The apparatus of claim 7, further comprising aseamer member adapted to periodically engage the first follower memberas the wheel rotates.
 13. A method of making absorbent articles havingside seams, the method comprising the steps of: cutting a web intodiscrete blanks; transferring the blanks onto folding mechanismsdisposed on a wheel rotating around a rotation axis, wherein eachfolding mechanism comprises: a first follower member movably connectedwith the first track, the first follower member having a proximal endportion and a distal end portion, a carrier arm pivotally connected withthe first follower member, a gripper member connected with the carrierarm, and a second follower member connected with the carrier arm andmovably connected with the second track; moving the distal end portionof the first follower member in a first orbit path about the rotationaxis in correspondence with a first circumferential shape defined by thefirst track; and actuating the folding mechanisms to fold the blanks bymoving the second follower member relative to the first follower memberin correspondence with a relative radial distance between the firsttrack and the second track.
 14. The method of claim 13, furthercomprising the step of periodically engaging a seamer member with thefirst follower member.
 15. The method of claim 13, further comprisingthe step of rolling a first roller member connected with the proximalend portion of the first follower member along the first track.
 16. Themethod of claim 15, further comprising the step of rolling a secondroller member connected with the second follower member along the secondtrack.
 17. The method of claim 13, wherein the first orbit path isdefined by a varying distance from rotation axis.
 18. The method ofclaim 13, wherein the first track comprises a curved portion and astraight portion.
 19. The method of claim 18, wherein the second trackcomprises a curved portion and a straight portion.
 20. The method ofclaim 13, further comprising the step of removing folded blanks from thefolding mechanisms.